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AIRBUS<br />
<strong>Aging</strong> <strong>Aircraft</strong> <strong>Program</strong><br />
Systems & Wiring<br />
Presented by René SAVOIE<br />
Task 2 Working Group member<br />
Seattle November 2001<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 1 SEE5a 956.0503/01 Nov 01
�<br />
General<br />
Contents<br />
• Airbus participation to ATSRAC phase 1<br />
– Sampling inspection of the fleet<br />
– Review fleet service history<br />
– Improvement of maintenance criteria<br />
– Electrical wiring standard practices manual<br />
– <strong>Aircraft</strong> wiring systems training<br />
• Airbus participation to FAA <strong>Aging</strong> Mechanical Systems<br />
program<br />
• Airbus participation to ATSRAC phase 2<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 2 SEE5a 956.0503/01 Nov 01
Airbus participation to ATSRAC Phase 1<br />
<strong>Aging</strong> transport systems rulemaking advisory committee - ATSRAC<br />
1998 - 2000<br />
TASK 1<br />
Sampling<br />
Inspection<br />
FedEx<br />
R .Pope<br />
Intrusive<br />
inspection<br />
AIB: D. Mazzarino<br />
TASK 2<br />
Fleet Service<br />
History review<br />
FedEx<br />
R. Pope<br />
AIB: R. Savoie<br />
Non Intrusive<br />
inspection<br />
AIB: C. Kane<br />
TASK 3<br />
Maintenance<br />
Criteria<br />
Airbus<br />
T. Harbottle<br />
TASK 4<br />
Std. Wiring<br />
Practices<br />
SAE<br />
Dave Allen<br />
AIB: T. Poole<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 3 SEE5a 956.0503/01 Nov 01<br />
TASK 5<br />
Review<br />
Training<br />
Boeing<br />
P. Lapwood<br />
AIB: JP. Capo
�<br />
Phase 1 - Sampling Inspection of the fleet<br />
Task 1 - Airbus work<br />
• Situation from each of the 5 A300 significant items<br />
Action Issue date Compliance<br />
Title Comments<br />
ISB<br />
24-0094<br />
MPD-Intro<br />
MSB<br />
24-0097<br />
Planned<br />
end 2001<br />
Planned<br />
mid 2002<br />
MPD-Intro Planned<br />
mid 2002<br />
MSB<br />
24--0096<br />
Planned<br />
end 2001<br />
Planned<br />
end 2001<br />
R Clamp slippage on strut in zone 270<br />
R<br />
R<br />
R<br />
R<br />
Bundle sagging<br />
Conduit clamping at conduit end<br />
ESPM 20-52-13 repair section provides enhanced<br />
technical process for improved gripping of the<br />
clamping attachment when found loose<br />
ESPM 20-52-13 repair section provides enhanced<br />
technical process for improved gripping of the<br />
clamping attachment when found loose<br />
ESPM 20-52-13 repair section provides enhanced<br />
technical process for improved gripping of the<br />
clamping attachment when found loose<br />
Bundle contacting structure at 811VU IPC 31-16-12 will reflect the latest installation<br />
configuration after MOD/SB embodiment reporting<br />
Bracket unstuck in 800VU IPC31-16-11 will reflect the latest installation<br />
configuration after MOD/SB embodiment reporting<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 4 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - Sampling Inspection of the fleet<br />
Task 1<br />
- Conclusion<br />
Status for Airbus: No wiring / wire type airworthiness<br />
concern requiring immediate action on the Airbus fleet<br />
Each findings from the 10 A300 inspections reviewed<br />
& investigated due to their repeat occurrence<br />
None of the five classified as an airworthiness concern<br />
Fixes for the five items defined. SBs, SBs,<br />
enhanced<br />
guidelines and processes to prevent similar conditions<br />
provided through SIL 92-004 dated April 30 / 01<br />
Enhanced awareness of maintenance personnel on wiring<br />
issues is necessary. Training is the key.<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 5 SEE5a 956.0503/01 Nov 01
� Task 2<br />
OIT<br />
Operator<br />
Information<br />
Telex<br />
Phase 1 - Review of fleet service history<br />
• Review existing airworthiness directives, service data<br />
and service experience:<br />
SBs<br />
Service<br />
Bulletins<br />
AD/CN<br />
Airworthiness<br />
Directives/<br />
Consigne de<br />
Navigabilité<br />
SIL<br />
Service<br />
Information<br />
Letter<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 6 SEE5a 956.0503/01 Nov 01<br />
AOT<br />
All<br />
Operator<br />
Telex
273<br />
AD<br />
Phase 1 - Review of fleet service history<br />
� Task 2<br />
93<br />
AOT<br />
SB<br />
+ + + + + +<br />
• 52 documents (mainly ( mainly SB’s) SB’s further reviewed for<br />
reassessment of Failure Mode Effect Analysis (FMEA)<br />
• Result: Result<br />
- Airbus review of service history/document<br />
• Significant numbers of documents have been<br />
scanned: scanned<br />
259<br />
OIT<br />
– 1 CN to be revised to reflect content of AD 84.066.061<br />
– 3 SB ’s upgraded from recommended to mandatory<br />
– 5 SB’s upgraded from desirable to recommended<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 7 SEE5a 956.0503/01 Nov 01<br />
484<br />
CN<br />
About<br />
3000<br />
750<br />
SIL<br />
About<br />
30000<br />
ISP
Phase 1 - Review of fleet service history<br />
� Task 2 -<br />
Conclusion<br />
All ASTRAC queries have been fully answered<br />
Status for Airbus: Airbus few SB revisions issued, issued Customers<br />
informed with OIT’s and SIL 92-004<br />
A300 recommendations validated on A310/A300-600 A/C<br />
(Airbus Airbus volontary basis) basis<br />
A310/A300-600 service history/document review<br />
planned in<br />
Similar A310/A300-600<br />
planned in 2002 (Airbus ( Airbus volontary basis) basis<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 8 SEE5a 956.0503/01 Nov 01
Phase 1 - Improvement on Maintenance Criteria<br />
� Task 3 - Implementation of new logic on A300<br />
• Airbus plan to apply EZAP to the A300 as soon as<br />
possible - target mid 2002<br />
• An industry working group will be formed with<br />
operators and Authorities<br />
• A new Zonal Inspection <strong>Program</strong> will be developed<br />
using MSG-3 logic<br />
• For A300, A300,<br />
promulgation of the new ZIP and the tasks to<br />
be added to operators Systems & Power Plant<br />
programs will be by Inspection Service Bulletin (ISB),<br />
• reflected in the Maintenance Planning Document (MPD) ( MPD)<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 9 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - Improvement on Maintenance Criteria<br />
Implementation of new logic on A310/A300-600<br />
• Time scale for application on A310/A300-600 not yet<br />
identified<br />
• Work will be done through the existing Industry<br />
Steering Committee under the Maintenance Review<br />
Board (MRB) process<br />
• New tasks developed will be added to an updated<br />
MRB Report and reflected in the MPD<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 10 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - Improvement on Maintenance Criteria<br />
Task 3 - Conclusion<br />
EZAP developed to enable closer attention to be given to<br />
wiring during maintenance program development<br />
Operators will need to address the consequences of the<br />
Task 3 activity relating to new maintenance tasks, revised<br />
inspection criteria and enhanced maintenance practices<br />
Taken together, these actions will result in a significant<br />
enhancement in the condition of wiring installations<br />
Airbus has initiated the process that will lead to<br />
application of EZAP on its aircraft types<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 11 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - Electrical wiring Standard Practices Manuals<br />
Task 4 - ESPM & Associated Documentation<br />
Scheduled<br />
maintenance<br />
MPD<br />
Maintenance<br />
Planning<br />
Document<br />
AMM MPD Task<br />
Inputs<br />
from<br />
WG 4<br />
Inputs<br />
from<br />
WG 3<br />
ESPM<br />
Airbus launched Generic<br />
ESPM ESPM - - April April 2001 2001<br />
WIRING FAULT<br />
Inputs<br />
from WG<br />
1, 2 & 4<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 12 SEE5a 956.0503/01 Nov 01<br />
Unscheduled<br />
maintenance
�<br />
Phase 1 - Electrical wiring Standard Practices Manuals<br />
Task 4 - Scheduled Maintenance Links<br />
ESPM 20-53-00 Inspection criteria<br />
A300<br />
24-92-19 Page 601<br />
ESPM<br />
Probable future implementation for the A300/A310/A300-600<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 13 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - Electrical wiring Standard Practices Manuals<br />
Task 4 – Conclusion (as applicable to Airbus) Airbus<br />
ASTRAC Task Groups’ recommendations are being applied<br />
in Airbus documentation<br />
Airbus generic ESPM applicable to all Airbus a/c is available<br />
Enhanced ESPM will include “Maintenance Tips” resulting<br />
from ATSRAC recommendations<br />
Airbus will continue to promote the efficient use of all<br />
maintenance manuals by<br />
– Documentation familiarization courses (on-site)<br />
– “How To Use” section in the “Introduction” of all manuals,<br />
including practical examples<br />
– User-friendly training and consultation media (Cadets)<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 14 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - <strong>Aircraft</strong> wiring systems training<br />
Task 5 - Airbus wiring systems course project<br />
• Airbus course program development planned<br />
• Customized to cover all Airbus aircraft family<br />
• Based on ATSRAC task 5 curriculum and lesson plans<br />
• Theoretical: 50% / Practical: 50%<br />
• Minimum 1 week course<br />
(expandable as required or necessary)<br />
• Course development completion and availability<br />
planned end 2002<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 15 SEE5a 956.0503/01 Nov 01
�<br />
Phase 1 - <strong>Aircraft</strong> wiring systems training<br />
Task 5 - Airbus wiring systems course (cont’d cont’d)<br />
• Objective is to develop an effective and attractive<br />
training course, balancing<br />
– Media, films, pictures presentation<br />
– Hands-on components / documentation familiarization<br />
– Troubleshooting Troubleshooting<br />
exercises with<br />
• Line-oriented scenarii to solve problems<br />
• Actual standard tool kit for practical repairs<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 16 SEE5a 956.0503/01 Nov 01
�<br />
CD-ROM<br />
Wiring<br />
Systems<br />
Training<br />
Course<br />
Video clips<br />
Pictures<br />
Phase 1 - <strong>Aircraft</strong> wiring systems training<br />
Wide range of training media<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 17 SEE5a 956.0503/01 Nov 01<br />
Hard-copy<br />
+ CD-ROM<br />
ESPM<br />
Microfilms<br />
WDM (AWM,<br />
ASM, AWL)<br />
CD-ROMs CD-ROMs<br />
CAATS<br />
ADRES<br />
TPCI
�<br />
Connector<br />
Assembly<br />
Disassenbly<br />
Phase 1 - <strong>Aircraft</strong> wiring systems training<br />
Standard tool kit for hands-on repair practice<br />
Wire<br />
stripping<br />
Contact<br />
crimping<br />
Insertion<br />
Extraction<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 18 SEE5a 956.0503/01 Nov 01<br />
Splice<br />
assembly<br />
Solder<br />
Sleeve<br />
&<br />
sleeve<br />
heat-shrink heat shrink<br />
Electrical<br />
test<br />
meters
�<br />
Phase 1 - <strong>Aircraft</strong> wiring systems training<br />
Task 5 - Conclusion<br />
Feedback received from airlines, repair stations & industry<br />
+ Recommendations from task task<br />
1, 3, and 4 WGs<br />
+ Assessment of the effectiveness of current training<br />
programs<br />
= Model Curriculum with detailed lesson plans on aircraft<br />
wiring systems developed & provided to operators (SIL 00-076)<br />
This training Model will effectively focus greater attention<br />
on the issue of aging wiring systems<br />
Airbus course availability planned end 2002<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 19 SEE5a 956.0503/01 Nov 01
Phase 1 - Conclusion<br />
� Atsrac phase 1 (1998-2000) - Summary<br />
FAA has launched an ambitious & aggressive program<br />
on <strong>Aircraft</strong> system aging<br />
Airbus has actively participated in ATSRAC, providing<br />
expertise and resources to all working groups<br />
Airbus operators have been regularly informed<br />
through the Operator Operator<br />
Information nformation Telex elex (OIT) channel<br />
More details details<br />
on the ATSRAC tasks and results are<br />
provided through Service Information Letters (SIL)<br />
Airbus also encourage operators to visit the FAA web<br />
site (www ( www.mitrecaasd mitrecaasd.org org/atsrac atsrac/) /)<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 20 SEE5a 956.0503/01 Nov 01
�<br />
Airbus participation to FAA ‘s <strong>Aging</strong> Mechanical System program<br />
Phase 1 (2001-2003) - Flight Control Systems<br />
• Airbus supports the new FAA’s research program to<br />
evaluate aging mechanical system processes to continued<br />
operational safety<br />
• Airbus will contribute to :<br />
– the assessment of design & manufacture’s maintenance<br />
instructions on the A320 Flight Control system Yaw axis<br />
– the assessment of maintenance & service history<br />
associated with this flight control system<br />
– the assessment of the condition of flight control linkages<br />
on aging aircraft (SEDLP)<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 21 SEE5a 956.0503/01 Nov 01
�<br />
Airbus participation to ATSRAC Phase 2<br />
<strong>Aging</strong> transport systems rulemaking advisory committee - ATSRAC<br />
2001 - 2002<br />
TASK 6<br />
Wiring<br />
certification<br />
Airbus / Boeing<br />
AIB: Jean-Luc<br />
Ballenghien<br />
Atsrac phase 2 (2001-2002) - On-going<br />
TASK 7<br />
Electrical Std<br />
Practices<br />
Airbus / Boeing<br />
AIB: Tony<br />
Poole<br />
TASK 8<br />
Wiring Systems<br />
Training<br />
FDX / DLH<br />
AIB: Jean-<br />
Pierre Capo<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 22 SEE5a 956.0503/01 Nov 01<br />
TASK 9<br />
Maintenance<br />
criteria<br />
NWA / VIR<br />
AIB: Tony<br />
Harbottle
�<br />
Phase 2 - Conclusion<br />
Atsrac phase 2 (2001-2002) - On-going<br />
FAA & JAA will implement ATSRAC recommendations<br />
Proposed rulemaking advisory advisory<br />
material expected from<br />
2002 onwards<br />
OAMs, OAMs,<br />
STC applicants, operators, PMIs, PMIs,<br />
ACOs will<br />
be affected<br />
Airbus, Boeing, Bombardier, Dassault, Dassault Embraer fully<br />
involved with FAA and ATSRAC to enhance aircraft<br />
design, maintenance and safety<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 23 SEE5a 956.0503/01 Nov 01
Thank you for your attention<br />
<strong>Aging</strong> <strong>Aircraft</strong> - - Systems & Wiring - - General 24 SEE5a 956.0503/01 Nov 01
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